Hydraulic Setting Chamber Isolation Mechanism From Tubing Pressure During Production And Stimulation Of The Well

ABSTRACT

Systems and methods of the present disclosure relate to isolating a setting chamber of an actuating assembly from tubing pressure. The actuating assembly comprises a cylinder; a mandrel disposed within the cylinder, the cylinder operable to move along the mandrel; a piston disposed between the cylinder and the mandrel, the piston operable to move along the mandrel in a direction opposite to that of the cylinder; a chamber disposed adjacent the piston, wherein the mandrel includes a port operable to allow fluid to pass into the chamber from the mandrel; and a spring disposed adjacent to the piston, the spring operable to expand, upon release of pressure from the chamber, to move the piston to seal the port and isolate the cylinder from pressure within the mandrel.

BACKGROUND

In preparation for production operations, a well packer may be run into a wellbore on a conveyance such as a work string or production tubing, for example. The packer supports the production tubing and other completion equipment, such as a sand control screen adjacent to a producing formation.

The packer also seals the annulus between the outside of the production tubing and the inside of the well for zonal isolation. The packer also carries annular seal elements that are radially expandable to seal against walls of the well, in response to axial compressive forces. Hydraulic actuation may be employed to cause longitudinal movement of packer components to expand the seal elements radially.

For example, packers such as hydraulic set production and service packers may include a setting chamber to provide a setting force to set elements and slips by applying pressure in tubing against an annulus in a wellbore. A setting area for a packer may include a contact area between a cylinder's inner diameter (ID) and a mandrel outer diameter (OD) in a set position.

In completions where multiple packers may be run in series, during stimulation or acid fracking of the bottom zones, upper zone packers may be subjected to the differential pressure from the tubing to the annulus. This scenario may also occur when the packer is set with underbalanced fluid in the tubing, or when a packer in series is sitting in a zone with the lowest reservoir pressure. Therefore, a cylinder of an upper zone packer must be strong enough to withstand the differential pressure. This may limit an ability to use a packer in high-pressure wellbore operation such as fracking, even though the packer seal elements may be qualified for higher pressure ratings.

Additionally, due to inherent material and design limitations, it may not be desirable to reduce the cylinder ID to withstand the differential pressure, as this reduction in ID reduces the setting area and thus reduces the setting force. In some cases, the cylinder ID may be reduced but another setting chamber may need to be introduced to compensate for the lost setting force, resulting in additional cost.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.

FIG. 1 illustrates an operating environment for an actuating assembly, in accordance with examples of the present disclosure;

FIG. 2 illustrates a close-up cutaway view of the actuating assembly in a run-in configuration, in accordance with examples of the present disclosure;

FIG. 3 illustrates a close-up cutaway view of the actuating assembly in a set configuration, in accordance with examples of the present disclosure;

FIG. 4 illustrates a run-in configuration for an alternate configuration of the actuating assembly, in accordance with examples of the present disclosure;

FIG. 5 illustrates a setting of the alternate configuration of the actuating assembly of FIG. 4 , in accordance with examples of the present disclosure;

FIG. 6 illustrates an after-setting alternate configuration of the actuating assembly of FIGS. 4 and 5 , in accordance with examples of the present disclosure; and

FIG. 7 illustrates an operative flow sequence for the actuating assembly, in accordance with examples of the present disclosure.

DETAILED DESCRIPTION

The present disclosure generally relates to systems and methods for isolating a cylinder of a downhole tool, such as, for example, a hydraulic set production packer or a service packer from a mandrel/tubular pressure after a setting or actuating process is complete. Isolating the cylinder may allow the packer to be exposed to the maximum rated differential pressure of its seal elements, rather than being limited by a pressure rating of another component of the packer such as, for example, the cylinder.

In particular examples, a floating piston may be disposed around a mandrel/tubular to isolate the cylinder from pressure within the mandrel. The piston may include at least two seals at its ID, and a spring may abut the piston to provide a spring force. Before setting, the piston may be locked in position via the cylinder and a stopper located at an end of the packer to allow setting of the packer.

During setting, the mandrel may receive a wellbore fluid (e.g., mud, water) via a hydraulic setting port(s) to cause the piston to move in a (e.g., down-hole) direction to energize the spring, while the cylinder simultaneously moves in an opposite direction (e.g., up-hole) to radially expand/set the packer.

Once the setting pressure/fluid is bled from the mandrel at the end of the setting process, the spring may expand to push the piston across the hydraulic setting ports. Then, a snap ring in the piston may lock it to the mandrel resulting in a set configuration where the mandrel/tubing pressure is isolated from the cylinder.

In some examples, seals (e.g., o-rings) disposed within recesses of the piston may be replaced with vee packing to improve reliability. The piston may also be pinned to the mandrel with shear pins or screws in a run position and may be actuated to shear the pins/screws upon the mandrel receiving a threshold fluid pressure/tubing pressure to move the isolation piston up-hole to close the setting port. Additionally, the packers, as described herein, may be employed in high-pressure fracking/stimulation jobs, as the packers are not limited by the cylinder burst rating.

It should be noted that the techniques as described herein may also be applicable to other downhole tools besides packers. For example, the systems and methods of the present disclosure may be used to isolate one chamber of a downhole tool from another chamber.

FIG. 1 illustrates an operating environment for an actuating assembly, in accordance with examples of the present disclosure. It should be noted that while FIG. 1 depicts an offshore environment, those skilled in the art may recognize that the principles described herein are equally applicable to land, without departing from the scope of the disclosure.

An offshore platform 100 may be positioned over a submerged subterranean formation 102 located below sea floor 104. The platform 100 may include a production platform, rig, or other suitable structure for subsea exploration and/or production operations. A conduit 106 extends from deck 108 to a wellhead 110. The platform 100 also includes a hoisting apparatus 112 (e.g., drawworks), a traveling block 113, and a derrick 114 for raising and lowering pipe strings such as a work string 116 which may include, for example, production tubing, tubing string, casing string, or other pipe disposed within casing string or open-hole sections.

A wellbore 118 (e.g., vertical and/or deviated) extends through the formation 102. In some examples, a casing string 120 may be cemented within the wellbore 118 via cement 122. The casing string 120 may extend from the wellhead 110 at or above ground level to a selected depth within the wellbore 118. The work string 116 may also include a packer 124 to provide zonal isolation for production, acidizing, or fracking operations.

In some examples, formation fluid(s) may pass into the wellbore 118 from a section 128 of the subterranean formation 102, via perforations 129. The packer 124 may include a hydraulic set production packer or a service packer and may include a packer seal element 126 disposed up-hole to an actuating assembly 130 operable to set/radially expand the seal element 126 in the wellbore 118. The packer 124 may be utilized in an open hole or cased hole. It should be understood that the configuration of packer 124 shown on FIG. 1 is merely illustrative and other configurations of the packer 124 may be used with the present techniques.

To set the packer 124, any suitable fluid such as mud or water/brine, for example, may be pumped downhole to actuate the actuating assembly 130 via a pump 132, a fluid source 134 (e.g., pit, tank), and a flow-in line 136 that is fluid communication with the packer 124 via the work string 116. In some examples, a valve 138 may be in fluid communication with the flow-in line 136 and may be operable to release pressure from the work string 116 to set the packer 124. Reduction in pumping pressure may also be used to reduce the pressure within the work string 116.

FIG. 2 illustrates a close-up cutaway view of the actuating assembly 130 in a run-in configuration, in accordance with examples of the present disclosure. The actuating assembly 130 may include a mandrel 200 extending through a cylinder 202. The mandrel 200 and the cylinder 202 may be concentrically arranged and the cylinder 202 may be operable to move in an axial direction indicated by directional arrow 204 upon actuation.

A retainer 206 may abut the seal element 126 and may be disposed between an OD of the mandrel 200 and an ID of the cylinder 202. The retainer 206 may be attached (e.g., welded) to the cylinder 202 and may be movable along the OD of the mandrel 200 to set/radially expand the seal element 126 via compression. The retainer 206 and the cylinder 202 may move in unison. In some examples, the retainer 206 and the cylinder 202 may be designed as a single piece component.

The retainer 206 may include a tubular member and may extend around the OD of the mandrel 200 and may include a recess 207 containing a seal 208 that may be in contact with the OD of the mandrel 200. The recess 207 and the seal 208 may extend along the OD of the mandrel 200. Also, a recess 209 containing a seal 210 may be in contact with the ID of the cylinder 202. The recess 209 and the seal 210 may extend along the ID of the cylinder 202. The seals 208 and 210 may each include an o-ring that extends around the mandrel 200.

A piston 211 may also be disposed between the OD of the mandrel 200 and the ID of the cylinder 202. The piston 211 may include a tubular member and may extend around the OD of the mandrel 200. The piston 211 may include recesses 212 and 214 that may extend along the OD of the mandrel 200. The recess 212 may include a seal 220 and the recess 214 may include a seal 222. Each of the seals may prevent leakage of fluid across the seal. Non-limiting example of the seals include o-rings.

The piston 211 may also include a recess 216 and a recess 218. The recess 216 may extend along the OD of the mandrel 202 and may include a component 224 such as a snap ring to restrict the movement of piston once it closes the fluid ports 226. The recess 218 may extend along the ID of the cylinder 202 and may include a seal 219 such as an o-ring extending along and contacting the ID of the cylinder 202. The cylinder 202 may include a no-go shoulder 225 to secure the piston 211 in place against the OD of the mandrel during run in hole. This ensures the piston 211 doesn't move up to close the flow ports 226 due to unintended pressure spikes.

The fluid ports 226 may be disposed on opposing sides of the mandrel 200. In some examples the ports 226 may be disposed in recesses 227. For example, the recesses 227 with the ports 226 may provide counterbores. The recesses 227 may be operable to receive the component 224, for example, to secure the component 224 (and piston 211) in place to close the ports 226.

The fluid ports 226 may allow fluid to flow from within a bore of the mandrel 200 into a chamber 228 defined between the OD of the mandrel 200, the ID of the cylinder 202, the retainer 206, and the piston 211. The chamber 228 may extend along the OD of the mandrel 200. Disposed adjacent to the piston 211 may be a spring 230 that abuts the piston 211.

The spring 230 may be compressed against a stopper 232 such as, for example, a tubular member disposed around the OD. The stopper 232 (e.g., a ring) may be secured in place via a fastener 233 such as a snap ring disposed in a groove 234 that extends along the OD of the mandrel 200. The stopper 232 may extend along the OD of the mandrel 200. The mandrel 200 may pass through the spring 230 and the stopper 232.

To actuate the actuating assembly 130, fluid 229 may pass into the chamber 228 from the mandrel 200 via the ports 226. During actuation, the cylinder 202 is subject to fluid pressure (e.g., setting pressure). The fluid pressure may simultaneously cause: (1) the retainer 206 and the cylinder 202 to move in an axial direction (e.g., indicated by the directional arrow 204) along the mandrel 200 to set the sealing element 126 and (2) the piston 211 to move in an opposite direction (e.g., indicated by a directional arrow 236) to compress/energize the spring 230 against the stopper 232.

It should be noted that in some examples, the directional arrow 204 indicates an up-hole direction and the directional arrow 236 indicates a downhole direction. In other examples, the directional arrow 204 indicates a downhole direction and the directional arrow 234 indicates an up-hole direction. After the setting process is complete, pressure may be bled/reduced from the chamber 228, via the ports 226, the piston 211 moves to seal the ports 226 due to expansion of the spring 230 and reduction of pressure within the chamber 228.

FIG. 3 illustrates a close-up cutaway view of the actuating assembly 130 in a set configuration, in accordance with examples of the present disclosure. The retainer 206 along with the cylinder 202 have moved axially toward the sealing element 126 to radially expand/set the sealing element 126 via compression.

The piston 211 has moved in the same direction as the retainer 206 and the cylinder 202, to seal the ports 226 with the seals 220, 222 due to expansion of the spring 230 and reduction of pressure within the chamber 228 due to release of the fluid 229. The component 224 locks the piston 211 together with the mandrel 200 once the setting ports 226 are closed.

Movement of the piston 211 is indicated by the directional arrow 300. In this sealed/set configuration, the cylinder 202 is isolated from pressure within the mandrel 200. The seals 220, 222 provide sealing barriers to assist in isolating the cylinder 202 from pressure within the mandrel 200 (e.g., tubing pressure).

FIG. 4 illustrates a run-in configuration for an alternate configuration of the actuating assembly 130, in accordance with examples of the present disclosure. A shear member 400 (e.g., pin or screw) may secure the piston 211 in place against the OD of the mandrel 200. This ensures the piston 211 doesn't move up to close the flow ports 226 due to unintended pressure spikes. The spring 230 is compressed but unable to shear the shear member 400 and move the piston 211 to close the port 226.

FIG. 5 illustrates setting of the alternate configuration of the actuating assembly 130 of FIG. 4 , in accordance with examples of the present disclosure. During the setting, fluid enters the port 226 and sets the actuating assembly 130, as shown on FIGS. 2 and 3 , for example. The tubing/mandrel pressure may shear the shear member(s) 400 and move the piston 211 to compress the spring 230 (e.g., compress the spring more than in the run configuration).

FIG. 6 illustrates an after-setting alternate configuration of the actuating assembly 130 of FIGS. 4 and 5 , in accordance with examples of the present disclosure. When the mandrel/tubing pressure is bled via port 226, the piston 211 moves to close/seal the port 226 due to expansion of the spring 230. The piston 211 may cease movement at a stop shoulder 600 on the mandrel 200. In this position, any tubing pressure does not enter the chamber 228 because the chamber 228 is isolated from the tubing pressure.

FIG. 7 illustrates an operative flow sequence for the actuating assembly, in accordance with examples of the present disclosure. At step 700, a packer may be disposed in a wellbore, as shown on FIG. 1 , for example.

In some examples, the packer may be run in the wellbore as shown on FIG. 4 , to prevent premature setting of the packer. That is, a shear member 400 may secure the piston 211 in place against the OD of the mandrel 200. The spring 230 is compressed but unable to shear the shear member 400 and move the piston 211 to close the port 226.

At step 702, the packer may be actuated as illustrated on FIGS. 2 and 3 . For example, as previously described, to actuate the actuating assembly 130, fluid 229 may pass into the chamber 228 from the mandrel 200 via the ports 226. Fluid may be pumped in from the surface of a well (e.g., as shown on FIG. 1 ). Alternatively, a port may be created by shearing a seal using a sleeve and running tool. In another alternate embodiment, tubing pressure and/or hydrostatic pressure may rupture a plug/rupture disk in order to initiate the setting process.

During actuation, the cylinder 202 is subject to fluid pressure. The fluid pressure may simultaneously cause: (1) the retainer 206 and the cylinder 202 to move in an axial direction along the mandrel 200 to set the sealing element 126, and (2) the piston 211 to move in an opposite direction to compress/energize the spring 230 against the stopper 232.

At step 704, pressure may be bled from the chamber 228, via the ports 226, and the piston 211 moves to seal the ports 226 due to expansion of the spring 230 and reduction of pressure within the chamber 228.

For example, pumping pressure may be decreased or a valve may relieve pressure from the actuating assembly 130, as shown on FIG. 1 , for example. At step 706, the cylinder 202 is isolated from tubing pressure as shown on FIG. 3 , for example.

Accordingly, the systems and methods of the present disclosure allow a cylinder of an actuating assembly to be isolated from tubing pressure. The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.

Statement 1. An actuating assembly comprises a cylinder; a mandrel disposed within the cylinder, the cylinder operable to move along the mandrel; a piston disposed between the cylinder and the mandrel, the piston operable to move along the mandrel in a direction opposite to that of the cylinder; a chamber disposed adjacent to the piston, wherein the mandrel is operable to allow fluid to pass into the chamber from the mandrel; and a spring disposed adjacent to the piston, the spring operable to expand, upon release of pressure from the chamber, to move the piston to seal the port and isolate the cylinder from pressure within the mandrel.

Statement 2. The actuating assembly of the statement 1, wherein the piston includes a seal.

Statement 3. The actuating assembly of the statement 1 or the statement 2, further comprising a snap ring.

Statement 4. The actuating assembly of any one of the statements 1-3, wherein the piston further comprises two additional seals adjacent to the snap ring.

Statement 5. The actuating assembly of any one of the statements 1-4, wherein the mandrel includes a recess.

Statement 6. The actuating assembly of any one of the statements 1-5, wherein the port is disposed in the recess.

Statement 7. The actuating assembly of any one of the statements 1-6, wherein the snap ring is operable for disposal within the recess.

Statement 8. The actuating assembly of any one of the statements 1-7, further comprising a shear member that secures the piston in place.

Statement 9. The actuating assembly of any one of the statements 1-8, wherein the piston is operable to receive fluid pressure from the chamber to shear the shear member.

Statement 10. The actuating assembly of any one of the statements 1-9, further comprising a stopper, wherein the spring is compressed between the piston and the stopper.

Statement 11. The actuating assembly of any one of the statements 1-10, wherein the spring is operable to expand upon a reduction of pressure within the chamber.

Statement 12. The actuating assembly of any one of the statements 1-11, wherein boundaries of the chamber are defined by at least the piston, the cylinder, and the mandrel.

Statement 13. A method for actuating an actuating assembly, comprising: passing fluid into a chamber from a mandrel via a port; moving a piston in a first axial direction to compress/energize a spring while simultaneously moving a cylinder in an opposite direction; compressing a spring disposed adjacent to the piston; releasing pressure from the chamber to expand the spring to move the piston to close the port; and isolating the cylinder from pressure within the mandrel.

Statement 14. The method of the statement 13, wherein releasing pressure from the chamber comprises releasing the fluid from the chamber.

Statement 15. The method of the statement 13 or the statement 14, further comprising disposing a seal into the port.

Statement 16. The method of any one of the statements 13-15, wherein disposing a seal into the port comprises disposing a snap ring into the port.

Statement 17. The method of any one of the statements 13-16, further comprising shearing a shear member to release the piston.

Statement 18. The method of any one of the statements 13-17, further comprising shearing the shear member due to pressure within the chamber.

Statement 19. The method of any one of the statements 13-18, further comprising securing a snap ring into the port.

Statement 20. The method of any one of the statements 13-19, further comprising moving the piston and the cylinder along the mandrel in axial directions.

Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted. 

What is claimed is:
 1. An actuating assembly comprising: a cylinder; a mandrel disposed within the cylinder, the cylinder operable to move along the mandrel; a piston disposed between the cylinder and the mandrel, the piston operable to move along the mandrel in a direction opposite to that of the cylinder; a chamber disposed adjacent to the piston, wherein the mandrel is operable to allow fluid to pass into the chamber from the mandrel; and a spring disposed adjacent to the piston, the spring operable to expand, upon release of pressure from the chamber, to move the piston to seal the port and isolate the cylinder from pressure within the mandrel.
 2. The actuating assembly of claim 1, wherein the piston includes a seal.
 3. The actuating assembly of claim 2, further comprising a snap ring.
 4. The actuating assembly of claim 3, wherein the piston further comprises two additional seals adjacent to the snap ring.
 5. The actuating assembly of claim 4, wherein the mandrel includes a recess.
 6. The actuating assembly of claim 5, wherein the port is disposed in the recess.
 7. The actuating assembly of claim 6, wherein the snap ring is operable for disposal within the recess.
 8. The actuating assembly of claim 1, further comprising a shear member that secures the piston in place.
 9. The actuating assembly of claim 8, wherein the piston is operable to receive fluid pressure from the chamber to shear the shear member.
 10. The actuating assembly of claim 1, further comprising a stopper, wherein the spring is compressed between the piston and the stopper.
 11. The actuating assembly of claim 10, wherein the spring is operable to expand upon a reduction of pressure within the chamber.
 12. The actuating assembly of claim 1, wherein boundaries of the chamber are defined by at least the piston, the cylinder, and the mandrel.
 13. A method for actuating an actuating assembly, comprising: passing fluid into a chamber from a mandrel via a port; moving a piston in a first axial direction to compress a spring while simultaneously moving a cylinder in an opposite direction; compressing a spring disposed adjacent to the piston; releasing pressure from the chamber to expand the spring to move the piston to close the port; and isolating the cylinder from pressure within the mandrel.
 14. The method of claim 13, wherein releasing pressure from the chamber comprises releasing the fluid from the chamber.
 15. The method of claim 13, further comprising disposing a seal into the port.
 16. The method of claim 15, wherein disposing a seal into the port comprises disposing a snap ring into the port.
 17. The method of claim 16, further comprising shearing a shear member to release the piston.
 18. The method of claim 17, further comprising shearing the shear member due to pressure within the chamber.
 19. The method of claim 13, further comprising securing a snap ring into the port.
 20. The method of claim 13, further comprising moving the piston and the cylinder along the mandrel in axial directions. 